MX2011012883A

MX2011012883A - Apparatus for and process of filling a muffler with fibrous material utilizing a directional jet.

Info

Publication number: MX2011012883A
Application number: MX2011012883A
Authority: MX
Inventors: Luc Brandt; Gunnar Nilsson; Lennart Svenson; Stefan Sjunnesson; Bengt-Erik Ingemansson
Original assignee: Ocv Intellectual Capital Llc
Priority date: 2009-06-03
Filing date: 2010-06-03
Publication date: 2012-01-12
Also published as: JP2012528987A; WO2010141681A1; ES2602002T3; EP2437894B1; EP2437894A1; RU2011145834A; JP5801292B2; PL2437894T3; KR101689911B1; HUE029671T2; US8590155B2; CN102458682B; US20100307632A1; CN102458682A; KR20140014400A

Abstract

A nozzle (22) for delivering texturized fibrous material into a chamber of a muffler has a body (26) including a texturized fibrous material passageway (28) and a separate directional jet passageway (30). A method of filling a chamber of a muffler with texturized fibrous material includes the steps of extending a wand (20) into the muffler so that a nozzle (22) on the wand is received in the chamber, discharging a stream of texturized fibrous material into the chamber from a first passageway (28) of the nozzle and discharging a directional jet (50) into the stream of texturized fibrous material from a second passageway (30) of a nozzle (22) whereby the stream of texturized fibrous material is redirected into a desired filling direction (52) to more efficiently fill the chamber.

Description

APPARATUS FOR AND PROCESS FOR FILLING A MUFFLER WITH FIBROUS MATERIAL USING A DIRECTIONAL JET TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION This invention relates in general to the field of production of silencers and more particularly to a novel apparatus and to a novel process for filling a silencer with textured fibrous material, using a directional jet of air.

BACKGROUND OF THE INVENTION Exhaust mufflers often include a sound-absorbing material inside the muffler to absorb and attenuate the sound made by the exhaust gases passing through the muffler. Many types of exhaust mufflers are produced by mechanically joining multiple pieces to form a muffler cover. For example, a common type of exhaust silencer is known as a centrifugal silencer. Centrifugal silencers are made by forming a sheet of material to the desired shape to form the body of the muffler and connecting end caps to this body by welding or folding to form the muffler cover. Another common type of exhaust silencer is a clam shell silencer, which is assembled by joining an upper section with a lower section by welding or folding. Both centrifugal mufflers and clam shell mufflers are generally divided into multiple chambers by baffles or divisions and contain perforated inlet and outlet tubes that extend between the chambers to feed and discharge the muffler gases.

A common material used to fill the exhaust mufflers are the continuous fibrous materials. The fibers usually fill one or more of the muffler chambers, and are often inserted into the muffler in a textured or "bulky" shape. In one approach, the bulked fibers are forced into the muffler cover assembled through either the inlet or outlet pipe. For better performance, it is important to provide a generally uniform distribution as well as fill density of the bulked fibers when forced into the cavities of the assembled muffler cover. There is a need for an improved muffler filling method that performs that function better.

COMPENDIUM OF THE INVENTION In accordance with the purposes of the present invention as described herein, an improved nozzle is provided for delivering textured fibrous material into a chamber of a silencer. The nozzle comprises a body having (a) a passage of textured fibrous material having an outlet gate for directing the textured fibrous material on a first path and (b) a directional jet passage having an exit orifice, for directing a directional jet on a second route that intercepts the first route to redirect the textured fibrous material into a desired fill direction. The body of the nozzle may further include an end cap. The end cap forms a cross flow channel portion of the directional jet passage.

More specifically, the nozzle includes an inlet end, a distal end and an axis A extending from the inlet end to the distal end. The first route forms an angle B with the axis A while the second route forms an angle C with the axis A where C < B. In a particularly useful embodiment which ensures a uniform, consistent and uninterrupted supply of the textured fibrous material while at the same time providing a more uniform distribution as well as filling density of a silencer chamber, the angle B is = 90 ° while the angle C < Four. Five. With this geometry, the desired fill direction forms an acute angle with the A axis to allow a more efficient filling of the silencing chamber.

According to another aspect of the present invention, a method for filling a chamber of a silencer with textured fibrous material is provided. This method includes the steps of extending a into the muffler, such that a rod nozzle is received in a chamber, discharging a stream of textured fibrous material into the chamber from a first passage of the nozzle and discharging a steering jet. within the stream of textured fibrous material from a second passage of the nozzle, whereby the stream of textured fibrous material is directed back to a desired filling direction to more efficiently fill the chamber.

More specifically, the method includes discharging the stream of textured fibrous material at an angle of at least 90 ° relative to an axis A of the nozzle, to ensure uniform flow of textured fibrous material from the nozzle. In addition, the method includes redirecting the stream of textured fibrous material within an acute angle of < 90 ° with respect to the axis A when the stream of texturized fibrous material with the directional air current impinges. By increasing or decreasing the pressure of the directional jet with respect to the pressure of the textured material stream, it is possible to adjust the desired fill direction of the redirected stream of textured fibrous material. In this way, the method also includes the step of changing the desired filling direction during the process of filling the muffler chamber with textured fibrous material.

The method also includes the steps of inserting the nozzle into the muffler through a pipe and extending the nozzle from an open end of the pipe to project into the chamber. The nozzle is then rotated about the axis A while discharging the stream of textured fibrous material into the chamber. Still further, the method includes the step of sealing an opening in an internal baffle of the muffler by plugging the opening with one end of the nozzle. This works to maintain or hold the textured fibrous material that is delivered through the nozzle into the desired chamber of the muffler.

In accordance with yet another aspect of the present invention, an apparatus for filling a muffler with textured fibrous material is provided. The apparatus comprises a texturizing gun, a first air source for providing air under pressure to the texturizing gun of a source of fibrous material that provides fibrous material to the texturizing gun. In addition, the apparatus includes a second source of air, a rod and nozzle assembly having a first passage for receiving the textured fibrous material from the texturizing gun and directing a stream of textured fibrous material into a muffler chamber over a first path and a second passage for receiving air under pressure from the second air source and directing a directional jet on a second path within the stream of textured fibrous material to redirect the stream of textured fibrous material within a desired fill direction to provide a more efficient filling of the camera. The body of the nozzle further includes an end cap that forms a cross flow channel portion of the second passage.

Still further, the nozzle includes an inlet end, a distal end and an A axis extending from the inlet end to the distal end. The first route forms an angle B with the axis A while the second route forms an angle C with the axis A where C < B. in a particularly useful embodiment the angle B 90 °, while the angle C is < Four. Five. As a result of this geometry, the desired filling direction forms an acute angle with the axis A which is useful in the efficient and uniform distribution of textured fibrous material in the chamber of a silencer.

In the following description, several different embodiments of the invention are illustrated and described, simply by way of illustration of some of the most suitable modes for carrying out the invention. As will be understood, the invention is capable of other different embodiments and its various details are capable of modification in various obvious aspects, all without departing from the invention. Accordingly, the drawings and description will be considered as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings incorporated herein and forming part of the specification, illustrate several aspects of the present invention and together with the description, serve to explain certain principles of the invention. In the drawings: Figure 1 is a schematic block diagram of the apparatus of the present invention; Figure 2 is a side elevation view illustrating the nozzle and the first and second passages passing through the nozzle; Figure 2A is a schematic view illustrating the angle C.

Figures 3A and 3B are different schematic cross-sectional views illustrating a muffler and the method of the present invention, whereby the apparatus is used to fill a chamber of that muffler with textured fibrous material; Y Figures 4A and 4B are detailed views in partial and schematic cross section, illustrating the method of the present invention.

Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES OF THE INVENTION Reference is now made to Figure 1 which schematically illustrates the apparatus 10 of the present invention. The apparatus 10 includes a texturizing gun 12 of a type well known in the art, for forcing compressed air into contact with the fibrous material and thus texturizing the packaging material in the chamber of a muffler. This textured gun 12 is described, for example, in U.S. Pat. Number 5,976,453 (Nilsson et al), owned by the Assignee of the present invention. The entirety of the U.S. Patent Number 5,976,453 is incorporated herein by reference. A first source of air 14 of pressurized air and a source of continuous fibrous material 16 are all connected to the texturizing gun 12. More specifically a wick or string (multifilament) of fibrous material is fed to the texturizing gun 12 from the source of fibrous material 16. The string of fibrous material is preferably a strand of multiple strands of straight fibrous materials, although it should be appreciated that any suitable fibrous material may be employed. Since the rope is fed through the textured gun 12, it enters a texturing chamber. A metered fluid of pressurized air from the first air source 14 is also introduced into the texturing chamber.

The compressed air within the texturizing chamber of the texturing gun 12 separates and flips the individual fibrous materials from the rope and the resulting texturizing fibrous material is propelled by the compressed air from the texturing gun into a rod, generally designated with the reference number 20. The rod 20 is hollow and includes a nozzle 22 and an extension 24. As will be described in greater detail below, the textured fibrous material of the textured gun 12 is transported through the rod 20 over a first or passage of textured material 28 while pressurized air from a second air source 25 passes through the rod over a second or directional jet passage 30.

Reference is now made to Figure 2 which shows in detail the nozzle 22. As illustrated in Figure 2, the nozzle 22 comprises a main body 26 which includes the first passage 28 for the textured fibrous material and a second passage 30 for receiving pressurized air from the second air source 25. As illustrated, the nozzle 22 includes a proximal or inlet end 32 connected to the extension 24 and a distal end 34 with a longitudinal axis A extending from the proximal end to the end distant. The body 26 also includes an end cap 36 held in place by a screw 38. The end cap 36 forms a cross flow channel portion 40 of the second or directional jet passage 30.

As further illustrated in Figure 2, the first passage 28 has an outlet gate 42 formed in the side wall 44 of the nozzle 22, such that a stream of textured fibrous material is discharged onto a first path 46 that forms a included angle B with axis A. Typically, the included angle B is = 90 °. Although the first passage is designed to form a 90 ° angle with the A axis, the textured material tends to escape through the main passage with a wide open angle (> 120 °) due to the short radial path.

In contrast, the second passage 30 includes an outlet hole 48 which directs the directional air jet 50 over a second path that intercepts the textured fibrous material in the first path 28, to redirect the textured fibrous material in a filling direction new or desired 52. As schematically illustrated in Figure 2A, the second route and the directional jet 50 form an included angle C of 15 ~ 45 ° with the axis A or a line parallel to the axis A. In the embodiment illustrated in FIG. Figure 2, the outlet hole 48 is located in the mouth of the outlet gate 42 and the directional jet 50 is directed back on a line parallel to the axis A in this way forming an angle C of 0o.

Overall, the geometry of the textured fibrous material stream of the first path 46 and the directional jet of the second path 50 ensures that the new direction 52 forms an acute angle D with the axis A. As will be appreciated, the acute angle D of the desired fill direction 52 for the textured fibrous material ensures that the fibrous material is blown back towards the direction of the extension 24. As will be described in greater detail below, this ensures better distribution of the textured and filled fibrous material most efficient one chamber of a silencer.

The method of the present invention will now be described with reference to Figures 3A, 3B, 4A and 4B. The Figures of Figures 3A and 3B describe a silencer assembly, generally designated by the reference numeral 100. The illustrated muffler assembly 100 comprises a main body portion 102 and end caps 104. In general the body portion 102 and the caps End pieces 104 are formed of a metal or metal alloy material, although it will be appreciated that any convenient material can be used for the body portion and end caps. The body portion 102 and the end caps 104 can be formed using any convenient forming process, such as forming with respect to a mandrel for the body portion 102 or die cutting for end caps 104. The body portion 102 and the end caps 102 end 104 are generally formed such that the complete silencer assembly 100 has an elongated elongated shape, with the main body portion joining with the end caps using any convenient method, such as welding or bending. It will also be appreciated, however, that other shapes and configurations may be employed, including for example clam shell type muffler configurations.

In the illustrated embodiment, gate openings 106 and 108 are provided in end cap 104. Port openings 106, 108 may be formed in or on end caps 104 in any convenient manner. For the best possible fiber distribution, the openings 106 and 108 should allow axial and radial displacement of the nozzle 22. In the illustrated embodiment, muffler tubes 110, 112 are received in the port openings 106, 108 respectively.

The silencer assembly 100 generally contains one or more internal structures. In the illustrated embodiment, the silencer assembly 100 includes two deflectors 114, 116 that divide the internal cavity of the silencer assembly 100 into three chambers 118, 120, 122. The first chamber 118 is provided between the end cap 104 and the deflector 114.

The second or intermediate chamber 120 is provided between the two baffles 114, 116. The third chamber 122 is provided between the baffle 116 and the end cap 104. An inner tube 124 extends through the two baffles 114, 116 and has a first end 126 in communication with the first chamber 118 and a second end 128 in communication with the third chamber 122. A flanged opening 132 is provided in the deflector 116. The opening 132 is in axial alignment with the opening 106 and is dimensioned and configured to facilitate insertion and subsequent fastening of the tube 110 to the baffle 116 as described below.

The second chamber 120 is filled with textured fibrous material by inserting the rod 20 into the tube 110 to the nozzle 22, including the outlet gate 42 and outlet port 48, extending from the open end 130. As illustrated, the end next 32 of the nozzle 22 is held in and substantially closes the end 130 of the tube. The tube 110 and the rod 20 then extend in the silencer assembly 100 through the gate opening 106. The tube 110 and the rod 20 are advanced until the free or distant end 34 of the nozzle 22 is received in the orifice 132 on the deflector 116. As illustrated, the nozzle 22 can convey an optional seal ring 60 adapted to couple and seal or seal the opening 132 in the baffle 116. As illustrated in Figure 4A, when the tube 110 and the nozzle 22 are suitably located in the silencer assembly 100, the proximal end 32 of the nozzle closes the tube 110, the distal end 34 of the nozzle seals the opening 132 in the deflector 116 by the seal ring 60 and the outlet gate 42 from the nozzle, it is opened to the chamber 120. Textured fibrous material is then discharged into the chamber 120 through the first passage 28 and the outlet gate 42 of the nozzle 22. The directional jet is simultaneously provided or discharged. RGA through the outlet orifice 48 when passing air under pressure through the second passage 30. By rotating the rod 20 and the nozzle 22 with respect to the axis A and varying the force of the directional jet, it is possible to control the direction in which the supplies the textured fibrous material from the nozzle 22 in the chamber 120. For example, the rod 20 and the nozzle 22 can be rotated 360 degrees or more about the axis A, such that the textured fibrous material is discharged upward toward down and sideways in all directions. In this way, it is possible to change the filling direction of the textured fibrous material stream during the chamber filling process as necessary to ensure the most efficient, effective and uniform filling of the chamber. As noted above, during the filling of the chamber 120 with textured fibrous material, the end of the nozzle 22 plugs the opening 132 in the baffle 116 to prevent the fibrous material from leaving the chamber 120.

After the chamber 120 has been filled with fibrous material, the rod 20 is slightly retracted in the direction of the action arrow F to retract into the tube 110, as the tube 110 is advanced in the direction of the arrow. action G such that the end 130 engages the baffle 116 in the margin around the opening 132 (see Figure 4B). This ensures that the fibrous material is maintained in the chamber 120 and does not enter the chamber 122. The rod 20 is then completely removed from the tube 110. The tube 110 is then connected or anchored in the deflector 116 in the flanged opening 132 by welding, expansion in the opening or other means.

Typically, the textured fibrous material is supplied through the first passage 28 and the exit gate 42 from the texturing gun 12 under a pressure of between about 1 and about 6 bars. In contrast, the directional jet is supplied on the second route 50 by directing air under pressure, at a pressure between about 1 and about 8 bars on the second route 30 through the exit port 48. The higher the directional jet pressure , more textured fibrous material is redirected at an acute angle to the baffle 114. Since the nozzle 22 is provided adjacent the baffle 116, the textured fibrous material now redirected by the directional jet 50 over the fill direction 52 to the baffle 114, it provides a more uniform distribution and filling density of the textured fibrous material through the chamber 120 of the baffle assembly 100.

It will be appreciated that through the filling process, air escapes under pressure through baffles 114, 116 within chambers 118, 122. Air can freely pass from chamber 122 to chamber 118 through tube 124 and air from chamber 118 can freely pass through. from tube 112 to the environment. This prevents accumulation of air pressure within the chambers 118, 120, 122 of the baffle assembly 100 that could otherwise slow the filling process or even damage the structure. It should be appreciated, however, that if desired, a vacuum generator can be connected to the end of the tube 112, to quickly remove air and assist in feeding texturized fibrous material through the rod 20 into the chamber 120.

The above description of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described. Modifications or obvious variations are possible in light of the previous teachings. The modalities here were selected and described to provide the best illustration of the principles of the invention and their practical application in order to allow a person with ordinary skill in the art to use the invention in various modalities and with various modifications such as suitable for the particular use contemplated. All these modifications and variations are within the scope of the invention as determined by the appended claims, when interpreted according to the extent to which they are entitled in a fair and equitable manner. The preferred drawings and embodiments are not and are not intended to limit in any way the ordinary meaning of the claims in their fair and broad interpretation.

Claims

1. A nozzle for supplying textured fibrous material in a chamber of a muffler, characterized in that it comprises: a body having (a) a passage of textured fibrous material having an outlet gate for directing the textured fibrous material on a first route and (b) ) a directional jet passage having an outlet orifice for directing a directional jet on a second route that intercepts the first route to redirect the textured fibrous material to a desired fill direction.

2. The nozzle in accordance with the claim 1, characterized in that it also includes an inlet end and a distal end, the nozzle includes an axis A extending from the inlet end to the distal end.

3. The nozzle in accordance with the claim 2, characterized in that the second route is parallel to axis A.

4. The nozzle according to claim 2, characterized in that the first route forms an angle B with the axis A, the second route forms an angle C with the axis A and C < B.

5. The nozzle according to claim 4, characterized in that the angle B > 90 degrees.

6. The nozzle according to claim 5, characterized in that the angle C < 45 degrees.

7. The nozzle according to claim 6, characterized in that the desired filling direction forms an acute angle D with the axis A.

8. The nozzle according to claim 1, characterized in that the body further includes an end cap, the end cap forms a cross flow channel portion of the directional jet passage.

9. A method of a filling chamber of a silencer with textured fibrous material, characterized in that it comprises: extending a rod inside the silencer, in such a way that a nozzle on the rod is received in the chamber; unloading a stream of textured fibrous material into the chamber from a first passage of the nozzle; and unloading a directional jet into the stream of textured fibrous material from a second passage of the nozzle, whereby the stream of textured fibrous material is redirected to more efficiently fill the chamber.

10. The method according to claim 9, characterized in that the nozzle includes an axis A and the method includes additional steps of inserting the nozzle into the silencer through a tube and extending the nozzle from one end of the tube to project into the chamber .

11. The method according to claim 10, characterized in that it includes rotating the nozzle with respect to the axis A while it is discharged into the stream of the textured fibrous material.

12. The method according to claim 11, characterized in that it further includes sealing an opening in an internal baffle of a muffler by sealing the opening with a distal end of the nozzle.

13. The method according to claim 12, characterized in that it also includes sealing the end of the tube with a proximal end of the nozzle.

14. The method according to claim 9, characterized in that it includes discharging the stream of textured fibrous material at an angle of at least 90 degrees from the axis A of the nozzle, to ensure uniform flow of textured fibrous material from the nozzle.

15. The method in accordance with the claim 14, characterized in that it includes redirecting the stream of texturized fibrous material at an acute angle less than 90 degrees to the axis A as the stream of textured fibrous material impinges with the directional jet.

16. The method in accordance with the claim 15, characterized in that it includes providing the nozzle in the chamber adjacent the first wall and directing textured fibrous material from the nozzle to a second opposite wall, to distribute more evenly and efficiently fill the chamber with the textured fibrous material.

17. The method according to claim 9, characterized in that it includes increasing or decreasing the pressure of the directional jet with respect to the pressure of the stream of textured material, in order to adjust the direction of the redirected stream of the textured fibrous material.

18. The method according to claim 17, characterized in that it includes changing the filling direction during filling of the chamber with textured fibrous material.

19. An apparatus for filling a silencer with textured fibrous material, characterized in that it comprises: a texturing gun; a first source of air that provides air under pressure to the texturing gun; a source of fibrous material that provides fibrous material to the texturizing gun; a secondary air source that also supplies pressurized air; a rod and nozzle assembly having a first passage for receiving textured fibrous material from the texturizing gun and directing a stream of textured fibrous material in a muffler chamber over the first path and a second passage for receiving air under pressure from the second path Air source and directing a directional jet on a second path in the stream of textured fibrous material to redirect the stream of textured fibrous material in a desired fill direction to provide more efficient filling of the chamber.

20. The apparatus in accordance with the claim 19, characterized in that the nozzle further includes a proximal end and a distal end, the nozzle includes an axis A extending from the proximal end to the distal end and wherein the first route forms an angle B with the axis A, the second route forms angle C with axis A and C < B wherein the angle B = 90 degrees and the angle C < 45 degrees.

21. The apparatus in accordance with the claim 20, characterized in that the desired filling direction forms an acute angle D with the axis A.

22. The apparatus according to claim 19, characterized in that the second route is parallel to axis A.